Tricks to a perfect 45 degree on rails?
 

What are the tips and tricks people are using to ensure a perfect 45 degree angle and what types of methods are people using to polish (Saw a wooden rig on the forum with sand paper) smooth so the bearings make contact on both sides perfectly?

From looking at the finish i did, i think it's more like 42 degrees and the bearings don't make contact properly. I have brand new disks to make the final pass before drilling and painting.

I assume the first issue relates to how perfectly the skate components have been bent but looking for advice on what has worked for my fellow MM builders.

Marco,
I cut a sample piece & tune the angle accordingly.
Grind a sample piece on both side & check with a set square.
You only need to set the correct angle once.

Thanks Ken, just got the set square out and can clearly see the improvements that need to be made and skate adjustments. Luckily i left enough material to be able to do a final pass?

What did you do to finish the rails...did you polish them or sanding using 240 grit paper?

I did a very light final pass over it & the rail turn out sparkiling. Used a diamond needle file to deburr the edges, did not touch the ground surface at all.
Don't forget to it down with a oil soaked rack to keep it from rusting...

I was wondering about those burs as well, they do make the bearings jump until they are sanded or cut off.

Always a good practice to remove burrs before they draw blood ;)

They are actually not that bad, the cutting disks and angle of attack on the angle iron produced a nice smooth finish on a downward cut method, you can definitively feel something is there ever so slightly. I have also use a silky type cloth that catches on anything as a guide to smoothness as well.

Thanks for the tips!